Orchestration Requirements for Modular Process Plants in Chemical and Pharmaceutical Industries

The increased flexibility resulting from the modularization of process plants requires an advanced strategy to supervise the distributed control systems (DCSs). The connection and coordination of multiple process equipment assemblies (PEAs) into a modular plant (MP) is called orchestration and conducted in a so‐called process orchestration layer (POL). Standardized interfaces enable a seamless integration of PEAs into an MP. Current process control systems do not yet meet all required features regarding to interfaces and possibility of import/export of different data structures. Several aspects are presented which shall be taken into account when designing a POL. The POL's several layers are described in detail, resulting especially in flexibility and reusability of modular plants.     

Flooding Prevention in Distillation and Extraction Columns with Aid of Machine Learning Approaches

Flooding of separation columns is a severe limitation in the operation of distillation and liquid-liquid extraction columns. To observe operation conditions, machine learning algorithms are implemented to recognize the flooding behavior of separation columns on laboratory scale. Besides this, the investigated columns already provided the modular automation interface Module Type Package (MTP), which is used for data access of necessary sensor data. Hence, artificial intelligence (AI) tools with deep learning offer high potential for the process industry and allow to capture operating states that are otherwise difficult to detect or model. However, the advanced methods are only hesitantly applied in practice due to complex combination of operational sensing, data analysis, and active control of the equipment. This article provides an overview on how AI-based algorithms can be implemented in existing laboratory plants. Process sensor data as well as image data are used to model the flooding behavior of distillation and extraction columns for stable and robust operational conditions.     

Implementation of the waste reduction (WAR) algorithm utilizing flowsheet monitoring

Environmental metric software can be used to evaluate the sustainability of a chemical based upon data from the chemical process used to manufacture it. An obstacle to the development of environmental metric software for use in chemical process modeling software has been the inability to obtain information about the process directly from the model. There have been past attempts to develop environmental metrics that make use of the process models, but there has not been an integrated, standardized approach to obtaining the process information required for calculating metrics. As a result, environmental evaluation packages are largely limited to use in a single simulation package, further limiting the development and adoption of these tools.This paper proposes a standardized mechanism for obtaining process information directly from a process model using a strongly integrated interface set, called flowsheet monitoring. The flowsheet monitoring interface provides read-only access to the unit operation and streams within the process model, and can be used to obtain the material flow data from the process streams. This material flow data can then be used to calculate process-based environmental metrics. The flowsheet monitoring interface has been proposed as an extension of the CAPE-OPEN chemical process simulation interface set.To demonstrate the capability of the flowsheet monitoring interfaces, the US Environmental Protection Agency (USEPA) WAste Reduction (WAR) algorithm is demonstrated in AmsterCHEM's COFE (CAPE-OPEN Flowsheeting Environment). The WAR add-in accesses the material flows and unit operations directly from the process simulator and uses flow data to calculate the potential environmental impact (PEI) score for the process. The WAR algorithm add-in is included in the latest release of COCO Simulation Environment, available from http://www.cocosimulator.org/.     

Investigation on and industrial application of degrading of methanol feed in methanol to propylene process

At present, methanol to propylene (MTP) technology developed by Lurgi Company is adopted for commercial plants and refined methanol with the purity ≥ 99.85 wt% is required as the feed of MTP unit in Lurgi's technology. Therefore, high energy cost for refined methanol production is one of the bottlenecks to improve the economy of MTP technology. Reducing the grade of feed refined methanol may be an effective method to save energy and reduce operation costs in MTP process. In this work, experiments and process simulation were carried out to investigate the influence and feasibility of degrading the methanol feed. Experiments were conducted to investigate the influence of crude methanol feed on conversion and selectivity of MTP reaction as well as the performance of ZSM-5 catalyst. The experimental results showed that degrading the methanol feed had no obvious influence on the conversion and selectivity of MTP reactions and the catalyst deactivation was caused by the carbon accumulation and metals deposition on the active sites. The process simulation results showed that the influence on the conversion and selectivity as well as the stream load of MTP process was negligible if 98mol% methanol was used as feed. Finally, industrial experiments were conducted by adjusting the operation parameters to degrade of feed methanol of the commercial 500 kt·a^-1 MTP unit of Ningmei Group in China. The results of industrial application illustrated that annually 180 kt fuel coal and 150 kt desalted water as well as1770 MW·h^-1 electricity would be saved when the water content increased from 0.01% to 0.4%. This work has identified the feasibility to improve MTP technology by degrading the methanol feed.     

The Potential Use of Ozone in Municipal Wastewater

This paper summarizes the potential options applying ozone for the improvement of effluents from wastewater treatment plants. A specific focus will be on the technical aspects of how to integrate ozone technique in existing or new conventional treatment plants. Additionally some large scale projects will be illustrated, where this technique is now in operation. The following aspects are of interest and are discussed: necessary ozone dose range (depends on application, water matrix and contaminants); required components of ozone systems (ozone generator, gas supply, reaction system, off-gas handling); process control, online measurement; potential parameters to be used for process control; design guidelines for the integration of ozone systems; and cost calculations.     

用于甲醇制烯烃的非均相催化反应器评述

甲醇制低碳烯烃（MTO、MTP）是煤化工的关键环节,近年来相关技术已经在我国成功工业化,包括中国科学院大连化学物理研究所的DMTO技术、中石化的s-MTO技术、UOP的MTO+OCP技术以及Lurgi的MTP技术。从非均相催化反应角度分析甲醇制烯烃的过程特点,剖析了各类典型的非均相催化反应器用于该过程的优劣,对比了国内外各主流技术的关键指标,评述了甲醇制烯烃和催化裂化的异同。分子筛催化的甲醇制烯烃过程遵循烃池机理,呈现自催化和积炭失活特性,控制催化剂的工作状态和限制返混对提高催化活性及烯烃产物选择性尤为重要。具有多级结构的分子筛催化剂及低返混流化床反应器或反应器串联组合是未来的发展方向。     

Development and deployment of an immersive learning environment for enhancing process systems engineering concepts

This work differentiates itself from most educational based multimedia resources by catering for two distinct audience groups. The first group is undergraduate process engineering students in a number of Australian institutions, whereas the second group represents operational staff at the industrial facilities covered by the interface. This presents challenges in pedagogy, educational pitch, industrial relations and project management. It has also added a sales driver to the project as we market the resource to industry as an operator training resource.The learning environment is based around spherical imagery of real operating plants coupled with interactive embedded activities and content. This virtual reality (VR) learning tool has been developed by applying aspects of relevant educational theory and proven instructive teaching approaches. Principles such as constructivism, interactivity, cognitive load and learner-centred design have been central considerations when constructing and structuring this resource. Structural challenges include determining a framework for the basic environment, the repository for the VR and activities, as well as the development of a learning platform arrangement to support self-directed learning in the interface. Some of the system's current functionality is demonstrated through snapshots of the screen configuration. Future developments within the interface are revealed.     

MTP反应中LPG的杂质对H-ZSM-5催化剂的影响

作为循环烃替代原料,国内某批次的液化石油气(LPG)中含有微量的杂质,且杂质含量高于Lurgi公司的甲醇选择性制丙烯(MTP)技术要求。本工作研究了该LPG中杂质对MTP催化剂结构和性能的影响。结果表明,LPG与甲醇共进料时,催化剂表现出了良好的催化活性、抗结焦性和再生性能。ICP测试显示在气相反应条件下,LPG中微量杂质在催化剂上未有明显的沉积现象。XRD表征说明反应前后和再生催化剂的骨架结构保存完好。NH3-TPD表征显示反应前后和再生催化剂的弱酸位数量未发生明显变化。这表明可以利用工业LPG作为循环烃的替代原料。     

Strategie zur festigkeitsmäßigen Auslegung von Druckbehälterkomponenten

Safety of equipment destined for the chemical and power generation industries is still mandatory. Structural changes in the equipment manufacturing industry and the current switch‐over to European and international standards harbour potential dangers which can ultimately manifest themselves in plant safety. Items of equipment used in process engineering are generally not mass produced articles with a generally valid safety standard. In contrast, they are subjected to specified loads and in this respect each one to be regarded as one of a kind. Strength testing is a mandatory requirement. This article considers a number of general points demanding attention in design work and future trends affecting design practice. The gap between research and everyday practice has to be bridged by applications‐orientated presentation of results. The paper presents a number of illustrative examples.     

Post-combustion CO2 capture with chemical absorption: A state-of-the-art review

Global concentration of CO₂ in the atmosphere is increasing rapidly. CO₂ emissions have an impact on global climate change. Effective CO₂ emission abatement strategies such as Carbon Capture and Storage (CCS) are required to combat this trend. There are three major approaches for CCS: post-combustion capture, pre-combustion capture and oxyfuel process. Post-combustion capture offers some advantages as existing combustion technologies can still be used without radical changes on them. This makes post-combustion capture easier to implement as a retrofit option (to existing power plants) compared to the other two approaches. Therefore, post-combustion capture is probably the first technology that will be deployed. This paper aims to provide a state-of-the-art assessment of the research work carried out so far in post-combustion capture with chemical absorption. The technology will be introduced first, followed by required preparation of flue gas from power plants to use this technology. The important research programmes worldwide and the experimental studies based on pilot plants will be reviewed. This is followed by an overview of various studies based on modelling and simulation. Then the focus is turned to review development of different solvents and process intensification. Based on these, we try to predict challenges and potential new developments from different aspects such as new solvents, pilot plants, process heat integration (to improve efficiency), modelling and simulation, process intensification and government policy impact.     

关矛Amberlyst40wet离子交换树脂脱除甲醇产品中三甲胺杂质的应用小结

介绍了Amberlyst 40wet离子交换树脂的性能参数；简述了树脂脱除甲醇产品中三甲胺的工艺流程；总结了树脂装填、预处理以及运行等方面的应用情况。结果表明：采用该技术，可使甲醇产品中的三甲胺含量降至50×10-9以下，满足了MTP催化剂的工艺要求。     

甲醇制烯烃反应工艺、反应机理及其动力学研究进展

甲醇制烯烃工艺近年来已成为煤化工领域的研究热点。不同的甲醇制烯烃催化剂将导致不同的反应过程,以SAPO-34为催化剂时,甲醇主要遵循烃池机理,通过快速的平行反应直接生产乙烯和丙烯(MTO)等低碳烯烃;以ZSM-5为催化剂时,甲醇主要遵循双循环机理中的烯烃循环机理,通过甲基化-裂解等多步反应间接生产丙烯(MTP)。这种反应特征的不同也决定着反应器类型和工艺条件的不同:SAPO-34催化剂易失活的特性决定了工业MTO过程通常采用易再生的流化床反应器从甲醇一步生成乙烯和丙烯,而具有良好抗结焦能力的ZSM-5催化剂使得工业MTP过程通常选择易放大的固定床反应器,通过大量烯烃循环与分离逐步获得丙烯。针对SAPO-34催化剂上MTO过程以及ZSM-5催化剂上MTP过程的不同反应情况,综述了近年来甲醇制烯烃代表性的反应工艺、反应机理以及反应动力学等方面的研究进展,并根据其存在的问题提出了相应的发展方向。     

Synthesis and characterization of a new family of cationic amino acid‐based poly(ester amide)s and their biological properties

A new family of positively charged and water soluble amino acid‐based poly(ester amide)s (PEAs) consisting of nontoxic L ‐arginine, diols, and aliphatic dicarboxylic acids building blocks was synthesized and characterized. The L ‐arginine based PEAs (Arg‐PEAs) were prepared by a solution polycondensation of two monomers: tetra‐p‐toluenesulfonic acids salts or hydrochloride acid salts of bis‐(L ‐arginine) α, ω‐alkylene diesters (monomer II ), and di‐p‐nitrophenyl esters of saturated or unsaturated dicarboxylic acids (monomer I ). Optimal reaction conditions were studied as functions of type of solvents and acid acceptors, concentrations of reactants. The molecular weights (M_n and M_w) of Arg‐PEAs measured by GPC ranged from 20,000 to 60,000 g mol^?1 with a rather narrow molecular weight distribution below 1.5. The chemical structures were confirmed by IR and NMR spectra. Arg‐PEAs obtained were all amorphous materials with T_g from 33 to 125°C, depending on the number and the type (saturated vs. unsaturated) of methylene groups in diols or diacids, and the type of counter‐ions attached to the guanidine group of the Arg‐based PEAs. The Arg‐PEAs had a high solubility in all polar solvents, including water. Preliminary studies of cell morphology and DNA capture capability of Arg‐PEAs indicated that this new family of cationic PEAs was nontoxic and more biocompatible than a commercial transfection agent (Superfect®), and can successfully capture plasma DNA. The strong positive charge of Arg‐PEAs as well as their good water solubility could provide unique characteristics for potential gene transfection or other charge preferred biomedical applications. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Schwimmende Produktionsanlagen für die Rohstoffgewinnung im Meer

Floating production plants. The growing trend towards production of raw materials such as oil, gas, and hard minerals from offshore deposits has led to the development of floating platforms for deep water applications. Process engineering aspects of producing oil and gas offshore and on floating platforms are discussed. While process engineering problems can be solved comparatively easily by methods adapted to the offshore environment, structural and operational problems of deep water platforms require more large-scale development and particularly expensive technical experience.     

新型丙烯生产技术综述

甲醇制丙烯是以丙烯为主要目的产物的甲醇制烯烃技术。甲醇制烯烃技术提供了一条不依赖石油的轻质烯烃生产路线,对于我国降低对进口石油的依赖、保障能源战略安全具有重要意义。综述了两种典型的甲醇制丙烯工艺的技术特点及其优缺点,并对相关技术最新的工业化进程进行了介绍,同时介绍了相应的烯烃分离技术。结合甲醇制丙烯技术当前的现状,对其面临的主要问题和未来的发展方向做了阐述。     

Die Rolle der Sensoren in der Verfahrenstechnik

The role of sensors in process engineering. The principal function of sensors in process engineering is to obtain information about an ongoing process in order to ensure optimum management of that process in terms of process engineering. New methods of measuring conventional parameters, and recent advances in instrumentation technology, have improved ways of obtaining information and so influenced the interpretation of process engineering installations. Statistical evidence confirms a sharp increase in the number of sensors, and the increasing tendency to record flow and level measurements and product composition. Changes occurring in process engineering determine the requirements sensors have to meet and the ways in which they can be used. Microelectronics makes it possible to extend the range of functions available and the information content. This is giving rise to an new generation of sensors which are not only helping to meet the higher measurement standards required but are also making modern sensor technology more ?user friendly”?, specially for maintenance.     

A method of alarm system analysis for process plants

The design and improvement of alarm systems in process plants has been given considerable attention recently. A methodology is presented in this paper which can be used as an aid in the design of new alarm systems or in the improvement of existing alarm systems. The methodology is incorporated in computer software into which expert knowledge of a given process plant can be entered and used to select alarm systems.

Scope—Alarm systems play a very important role in process plants. They aid the operator in his primary tasks of detecting and interrupting progression of a failure, and diagnosing and providing corrective actions for fault conditions. There are, however, operator difficulties in handling alarms. A particular alarm system design can significantly affect the operator's success likelihood in receiving and processing alarms.

Several factors are important in the design or improvement of a given system. Human likelihood of success using a given alarm system under a given fault condition is one obvious factor. Economical aspects of selecting alarm systems, given probable types and frequencies of fault conditions, should also be considered in the design or improvement of alarm systems. A systematic approach is necessary to consider the effects of all these factors in evaluating a set of proposed alarm systems and in selecting the most appropriate alarm system. The purpose of this paper is to provide a method for determining the worth of a given alarm system by considering all factors which influence that worth.

In complex process plants, applications of the methodology presented in this paper can be very difficult without the aid of a computer. Therefore, a computer program is also described to carry out the methodology. Information regarding the process plant is entered into the program using the goal-tree concept. The goal tree contains the expert knowledge of the process which in turn is used in the design or modification of alarm systems.

Conclusions and Significance—A methodology has been presented to perform systematic evaluation of alarm systems. The methodology is based on the goal-tree concept through which process plants can be modeled.

Goal trees excellent tools for cause-consequence determination. The methodology makes use of decision trees which are constructed in parallel to goal trees to show all operator action(s) required to achieve each goal, and to show the consequences of operator's failure to achieve each goal. The decision trees can also model the progression of an initiating fault condition. The operator's likelihood of success of achieving each goal for a given alarm system design or alarm system modification can be estimated and used in the decision tree to estimate anticipated consequences of a given alarm design or modification. Anticipated consequence is defined as the probability of not achieving a goal times the consequence of not achieving that goal. Finally, alarm system designs or modifications with a low anticipated consequence and low implementation cost can be identified for further evaluation as potential alarm systems for the process.

The methodology has been modeled in a system of computer codes called UMPIRE-I. Process knowledge is entered into the computer through a goal tree coupled with human success likelihoods. The rest of the analysis is performed by UMPIRE-I. The code is user-friendly and can be used with minimal training. An example is provided in the paper to further clarify the methodology.

This method has been applied to several limited-scale engineering processes with rather significant success.     

Thermoplastic polyester amides derived from oleic acid

Three lipid-based Polyester Amides (PEAs) with varying ratios of ester and amide linkages were synthesized. Oleic acid was used as the starting material to produce the intermediates, characterized by MS and NMR, used for polymerization. PEAs were characterized by FTIR and GPC. The PEAs were constrained to have similar number average molecular weights, in the 2 × 10⁴ range, thereby enabling comparison of their physical properties from a structural perspective. The thermal behavior of the polymers was assessed by DSC, DMA and TGA. Thermal degradation was not affected by ester/amide ratios, but T_g increased non-linearly with decreasing ester/amide ratios and correlated with hydrogen-bond density and repeating unit chain length. Crystallinity was studied by XRD and DSC. Degree of crystallization and multiple melting behavior as a function of cooling kinetics were explained well by hydrogen-bond density, repeating unit chain length and density of ester moieties. Mechanical properties were investigated by DMA and Tensile Analysis, with a non-linear increase of storage and tensile moduli recorded as a function of decreasing ester/amide ratios. The findings suggest how approaches to the synthesis of lipid-based PEAs can be targeted to the delivery of specific physical properties.     

界面相及其特性、表征与应用

提出了界面相的概念及利用界面相与主体相分离以实现溶质分离的设想;建立了测定界面相体积及组分在界面相与主体相之间分配比的实验方法,以葡萄糖为示踪剂,测定了Cu（Ⅱ）的分配比,考察了操作条件对界面相特性的影响。研究结果显示出气-液界面相分离方法在化工、环保及生物化工等领域具有广泛的应用前景。     

A contribution to the qualification process of surface pretreatment methods: Sensitivity of mechanical tests to adhesion and delamination

Focusing the adhesive bonding of thermoset carbon fiber reinforced plastics (CFRPs) due to release agent residues on a surface pretreatment prior to the bonding process is inevitable to guarantee sufficient adhesion. Based on different material and process-related phenomena, a huge variety of parameters (e.g. treatment time) influence the treatment effectiveness. This often leads to intense parameter studies in which pretreatment methods are qualified by different mechanical tests and which require significant effort in terms of time and resources. Those qualification procedures are sometimes standardized by different and mostly company-specific standards. To increase the efficiency of this qualification process by increasing the general validity, this paper presents a comparison of different mechanical test methods (namely single lap shear test, floating roller peel test, double cantilever beam (DCB) test, and cross-tension test) in terms of their sensitivity to the detection of adhesion or delamination defects, even if they normally test different aspects of a joint. However, it could be found that the most common test – the single lap shear test – can only reveal large defect levels, while different tests, e.g. DCB test, show a good sensitivity for all investigated failures and others show intermediate performance.